ACO Building Drainage. ACO Lipufloc dosing station. Operating instructions

ACO Building Drainage Operating instructions Issued: 2015-07-02 ACO Lipufloc dosing station Chemical-physical waste water treatment system to reduce...
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ACO Building Drainage Operating instructions

Issued: 2015-07-02

ACO Lipufloc dosing station Chemical-physical waste water treatment system to reduce concentrations of fats and oils in ACO grease separator outlets; for free-standing installation in frost-free areas and for below ground installation

To ensure safe and proper use, read the operating instructions and other literature supplied with the product carefully, provide end users with them and keep them safe throughout the service life of the product.

0150.46.71_V1.1_EN

Translation of the original instructions

ACO Lipufloc dosing station Willkommen 

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ACO Lipufloc dosing station Introduction

Introduction ACO Passavant GmbH (hereafter referred to as "ACO") would like to thank you for the confidence you have placed in us. You have purchased an ACO Lipufloc dosing station (hereafter referred to as "system"), which is a state-of-the-art solution that was tested prior to delivery as part of our quality control process to ensure it is in proper condition. Illustrations in this manual are provided for basic understanding and may vary depending on the system model and installation situation.

Service Please feel free to contact ACO Service if you require further information. ACO Service Im Gewerbepark 11c

Tel.: + 49 (0) 3 69 65 / 81 9 -4 44 Fax: + 49 (0) 3 69 65 / 81 9 -3 67

36457 Stadtlengsfeld, Germany

[email protected]

Product identification The type plate specifying the following data is attached to the inside of the cabinet door (above left): ■■

Product designation, type designation

■■

Year of construction

■■

Serial number

■■

Item no.

■■

Manufacturer’s address

Identify the system supplied using the specifications on the type plate and mark the respective system in the following table or enter missing data. Year of construction

Product

Item no. Serial no.

Model

ACO Lipufloc

7980.20.10

For ACO NS 4-25 grease separators with control unit (OA, OSE, OAE, RA, RSE, RAE); free-standing installation

ACO Lipufloc

7980.20.20

ACO NS 4-25 grease separators without control unit (O, OD, OS, R, RD, RS); Free-standing installation

ACO Lipufloc

7980.20.30

ACO grease separators; below ground installation

Warranty For information on warranties, see "General Terms and Conditions",  http://www.aco-haustechnik.de/agb

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ACO Lipufloc dosing station Introduction

Use of symbols Symbols are used to draw your attention to particular information in these operating instructions as follows: Tips and additional information to make your work easier ■■

Bullet point

ÎÎ

Steps to be carried out in the specified order References to further information in these operating instructions and in other documents Warnings

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ACO Lipufloc dosing station Contents

Contents 1

For your safety......................................................................................... 6 1.1 Intended use.............................................................................................. 6 1.2 Personnel qualification................................................................................ 7 1.3 Personal protective equipment..................................................................... 7 1.4 Warnings................................................................................................... 8 1.5 Owner's responsibility................................................................................. 9 1.6 Transport and storage.............................................................................. 10 1.7 Disposal.................................................................................................. 10

2

Product description................................................................................11 2.1 Scope of delivery..................................................................................... 11 2.2 Product features....................................................................................... 13 2.3 System layout.......................................................................................... 15 2.4 Operating principle................................................................................... 17 2.5 Control unit.............................................................................................. 18 2.5.1 Signal column................................................................................ 18 2.5.2 Touch panel................................................................................... 19

3 Installation.............................................................................................22 3.1 Requirements........................................................................................... 22 3.2 Installation............................................................................................... 22 3.3 Services provided by customer.................................................................. 22 4 Commissioning.......................................................................................23 4.1 Default settings on touch panel.................................................................. 23 4.1.1 Performance monitoring................................................................. 25 4.1.2 Setting automatic operation............................................................ 25 4.2 Day-to-day operation................................................................................. 26 4.3 Changing the flocculant............................................................................. 27 5 Troubleshooting......................................................................................30 6

Technical data........................................................................................33

Appendix 1: Commissioning report................................................................35

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ACO Lipufloc dosing station For your safety

1 For your safety Read the safety instructions before installing or using the system to prevent injuries and damage to property.

1.1 Intended use The system has been developed with the aim of treating waste water in the catering industry in a more advanced manner. The focus is on reducing the concentrations of greases and oils in grease separator outlets. As only freely separable substances, such as undissolved or emulsified grease/oils or solids from food preparation and meals, can be removed from the waste water stream in these systems, emulsified or dissolved waste water components end up untreated in the public sewer system. This mostly involves grease/oils that exist as stable emulsions and cause deposits and biogenic corrosion etc., which are responsible for damage to the public sewer system. ■■

These emulsions must be reduced in a targeted manner in the running waste water stream and locally applicable limit values for their concentrations in waste water must be adhered to and undercut if possible.

■■

The system is designed to permanently undercut the grease and oil concentration of 100 mg/l and must be used in conjunction with ACO grease separators.

■■

As it is specially adapted for use with the ACO Passavant GmbH range of grease separators, it cannot be used with third-party products.

No other possible uses or applications, nor modifications, are permitted. Improper applications Some examples of incorrect uses include: ■■

Using the system outside the scope of its application,

  Section 6 "Technical data"

■■

Letting the system or the pumps run dry

■■

Using worn components (failure to carry out maintenance)

■■

Ignoring these operating instructions and other documentation supplied with the product

■■

Use in areas where there is a risk of explosion

■■

Putting hazardous substances into the system

Non-approved parts Installing non-approved parts compromises safety and voids any warranty provided by ACO. Only use original parts from ACO or ACO-approved spare parts when replacing components.

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ACO Lipufloc dosing station For your safety

1.2 Personnel qualification Operations

Person

Knowledge Knowledge of building technology and building services and the standards and regulations to be applied

Design, changes in operation

Planner

Installation

ACO Service qualified technicians

Special knowledge with regard to preserving the value and functional reliability of the system

Electric installation

Electrician

Only electricians may establish connections to a power supply

Operations monitoring, weekly inspections

Owners, operators

No specific requirements

Commissioning, troubleshooting and maintenance

ACO Service qualified technicians

Special knowledge with regard to preserving the value and functional reliability of the system

Disposal

Qualified technicians

Correct, environmentally compatible disposal of materials and substances, knowledge regarding recycling

Assessment of applications for waste water technology and correct design of drainage systems

1.3 Personal protective equipment Personnel must be provided with personal protective equipment and its use checked by supervisors. Mandatory Explanation symbols Safety shoes offer good non-slip protection, especially in wet conditions, as well as high puncture resistance (e.g. in the case of nails) and protect feet from falling objects (e.g. during transportation). Safety gloves protect hands from infections (moisture-proof safety gloves) as well as from slight bruising and cuts, in particular during transportation, installation, maintenance and disassembly.

Protective clothing protects skin from minor mechanical damage and infections.

A safety helmet protects against head injuries, e.g. from falling objects or blows where there are low ceilings. Safety goggles protect eyes from injections, particularly during commissioning, maintenance and repair.

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ACO Lipufloc dosing station For your safety

1.4 Warnings Warnings are indicated in these operating instructions by the following warning symbols and signal words. Warning symbol and signal word

Explanation Hazard with a high degree of risk which, if not prevented, will result in death or serious injuries.

WARNING

Injuries

DANGER

Hazard with a low degree of risk which, if not prevented, may lead to minor or moderate injuries. Damage to property

CAUTION

ATTENTION

Hazard with a medium degree of risk which, if not prevented, may lead to death or serious injuries.

Hazard which, if not prevented, may damage products and their functions or an object in the vicinity.

1.5 Owner's responsibility Duty of care that falls under the owner's/operator's responsibility: ACO recommends keeping an operating log and documenting inspections, maintenance, repairs, etc. so that there is objective evidence in the event of an insurance claim being made. Planning and installation ■■

Plan, install and operate the system as specified by the manufacturer

■■

Professional installation in accordance with the specifications set out in these operating instructions

Operations monitoring ■■

Checking intended operation,

Kap. 1.1 “Intended use“.

■■

Checking the system e.g. for leaks, unusual operating noises.

■■

Checking the operational readiness of the system at the signal column, touch panel or control unit.

■■

Environmentally compatible disposal of the system contents.

Maintenance The system must be operated and maintained such that proper functioning and operational safety are ensured. We recommend that system operators make a maintenance contract for maintenance and servicing work to be performed on a regular basis.

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ACO Lipufloc dosing station For your safety

ACO Service would be pleased to have its experts perform the maintenance and servicing work. Request a maintenance contract [email protected]. Recommended maintenance intervals: ■■

Quarterly or every six months

Additional (uncommon) maintenance: ■■

After a flooding of the system

■■

Before recommissioning the system

1.6 Transport and storage The system with enclosure is delivered attached to a pallet (Euro pallet). Additional system components are supplied attached to a pallet (Euro pallet) and are foil-wrapped for protection against moisture and dirt. ATTENTION Observe the following with regard to storage and transportation: ■■

Store the system in frost-free rooms.

■■

Never drive a forklift or lifting truck directly under the system.

■■

If possible, transport the system on a Euro pallet.

■■

If possible, do not remove the packaging and transport safety devices until the system has reached the installation location.

■■

Check the load bearing capacity of the lifting gear: It must be at least equivalent to the indicated weight plus safety margin.

■■

When using a crane or crane hook to transport the system: ……

Fasten the belts to the pallet or to system components that can bear the load.

……

Never stand under a suspended load.

……

Make sure that no other people can access any part of the danger area.

……

Avoid swinging movements during transportation.

All other tasks, such as releasing the system parts from the enclosure or the pallet, transporting the parts to the actual assembly area, assembling the system parts and removing the enclosure, are carried out by ACO Service.

1.7 Disposal When decommissioning the system, empty it completely and clean it. Incorrect disposal constitutes an environmental hazard. Comply with regional disposal regulations. ■■

Separate components by materials

■■

Recycle components

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ACO Lipufloc dosing station Product description

2 Product description 2.1 Scope of delivery Model item no. 7980.20.10 and 7980.20.20 Unit Dosing station 155 kg

Individual parts

Illustration

Packaging

■■ Cabinet ■■ Dosing pump ■■ Transport cart ■■ Control unit ■■ Touch panel

Enclosure on wooden pallet

■■ Signal column ■■ Barrel cover with seal, tension ring,

suction attachment with foot valve, ultrasonic sensor ■■ ...

Circulation unit 35 kg

■■ 1x bracket ■■ 1x centrifugal pump with connecting

cable ■■ 1x diaphragm valve ■■ 1x injection valve ■■ Connection with ball valve

Box on wooden pallet

■■ Mounting with strainer ■■ Pressure and suction hose ■■ DN 100 T-piece with pipe connector ■■ DN 150 T-piece with pipe connector ■■ DN 200 T-piece with pipe connector ■■ Connector ■■ ...

■■ Cover with seal and tension ring ■■ Safety data sheet ■■ Label

Documentation

■■ Operating instructions ■■ Shipping papers

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ACO Haustechnik Reaktionstrennmittel PW Grease Flocculant Sicherheitsratschläge (lt. Sicherheitsdatenblatt): Von Kindern fernhalten! Nicht einnehmen!

Nicht gefrieren lassen!

Beschreibung (lt. Sicherheitsdatenblatt): Dosiermengen werden durch unser autorisiertes Fachpersonal festgelegt.

LTC 1433/02/2012

125 kg

■■ Barrel containing flocculant

Sach-Nr. 0150.41.49

Flocculant

Material-Nr.:

0155.01.30

Inhalt:

125 Kg

www.aco-haustechnik.de



Box on wooden pallet

PVC bag

ACO Lipufloc dosing station Product description

Design item no. 7980.20.30 Unit Dosing station 155 kg

Individual parts

Illustration

Packaging

■■ Cabinet ■■ Dosing pump ■■ Transport cart ■■ Control unit ■■ Touch panel

Enclosure on wooden pallet

■■ Signal column ■■ Barrel cover with seal, tension ring,

suction attachment with foot valve, ultrasonic sensor ■■ ...

Circulation shaft base 70 kg

■■ Base ■■ Sampling pot (for construction phase

1) ■■ Instructions for use 0170.29.02

Circulation unit 20 kg

Wooden pallet

■■ 1x bracket ■■ 1x submersible pump with connecting

cable ■■ 1x diaphragm valve ■■ 1x injection valve ■■ Pipeline

Box on wooden pallet

■■ Pressure hose for dosing ■■ Submersible pump of pressure hose ■■ Float switch with connecting cable ■■ Cable duct ■■ Connection seal ■■ ...

■■ Cover with seal and tension ring ■■ Safety data sheet ■■ Label

Documentation

■■ Operating instructions ■■ Shipping papers

ACO Haustechnik Reaktionstrennmittel PW Grease Flocculant Sicherheitsratschläge (lt. Sicherheitsdatenblatt): Von Kindern fernhalten! Nicht einnehmen!

Nicht gefrieren lassen!

Beschreibung (lt. Sicherheitsdatenblatt): Dosiermengen werden durch unser autorisiertes Fachpersonal festgelegt.

LTC 1433/02/2012

125 kg

■■ Barrel containing flocculant

Sach-Nr. 0150.41.49

Flocculant

Material-Nr.:

0155.01.30

Inhalt:

125 Kg

www.aco-haustechnik.de



Box on wooden pallet

PVC bag

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ACO Lipufloc dosing station Product description

2.2 Product features Short description of the system The system has been developed with the aim of treating waste water in the catering industry in a more advanced manner. The focus is on reducing the concentrations of greases and oils in grease separator outlets. The system is to be installed in a frost-free room. The cabinet is made from high-quality stainless steel. The control unit, dosing pump (hose pump) and the transport cart with the active agent (flocculant) are located in the cabinet. Combined with ACO grease separator in a free-standing position: The circulation unit is erected next to the free-standing grease separator. The mixing pump (centrifugal pump) is connected to the submersible outlet pipe of the grease separator via a suction hose and to the inlet of the grease separator with a pressure hose via a connector. A suction pipe is installed between the dosing pump and the container, and a pressure line between the dosing pump and mixing pump. Combined with ACO grease separator in a below-ground position: The circulation unit is installed in the underground circulation shaft. The circulation shaft is positioned downstream of the underground grease separator. The mixing pump (submersible pump) is connected to the submersible inlet pipe of the grease separator via a pressure line (pipeline and hose). A suction pipe is installed between the dosing pump and the container, and a pressure line between the dosing pump and mixing pump. A touch panel is fitted in the lockable door of the cabinet. All dosing settings and automatic processes are defined, displayed and controlled at the touch panel. System features: ■■

■■

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General information: ……

Ready to connect, quick to install

……

Low maintenance costs

……

Rapid top-up of active agent (flocculant)

……

All components have high chemical resistance

……

Suitable for waste water that contains grease and for ACO grease separators

Cabinet: ……

Material: stainless steel

……

Lockable door with touch panel

……

Lockable door for storing the active agent

……

Height-adjustable feet with rubber pads

……

230-V/50–60-Hz power socket (freely accessible on rear wall for on-site use)

……

Dosing pump

ACO Lipufloc dosing station Product description

■■

■■

■■

■■

Circulation unit for free-standing installation: ……

Strainer

……

Injection valve

……

Centrifugal pump

……

Diaphragm valve

……

Connector

Circulation unit for below ground installation: ……

Circulation shaft base

……

Submersible pump

……

Injection valve

……

Diaphragm valve

……

Connector

Control unit: ……

Touch panel (in cabinet door)

……

Signal column

……

Collective fault message (potential-free)

……

"Check treatment agent" operational message (potential-free)

Active agent: ……

Flocculant container for "ACO PW Grease Flocculant" – 125 kg/in accordance with WGK 1 (water hazard class), secured to transport cart and sealed and located in cabinet

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ACO Lipufloc dosing station Product description

2.3 System layout Model item no. 7980.20.10 and 7980.20.20 1

2

3

4

5

6

7

8

27

26

25

24

9

10

11

12

13

14

15

16

23

22

21

20

19

18

17

Illustration: 1 = Connector

15 = Control unit

2 = Pressure hose/mixing pump

16 = 230-V power socket (rear of the cabinet)

3 = ACO grease separator (optional)

17 = Transport cart

4 = Diaphragm valve

18 = Suction attachment with foot valve

5 = Connection socket

19 = Level-measuring device for container contents

6 = Ball valve

20 = Container for flocculant

7 = Connecting hose

21 = Cover with transparent inlay and tension ring

8 = Mixing pump for suction hose

22 = Cabinet

9 = Mounting

23 = Outflow part of grease separator (optional)

10 = Strainer

24 = Pressure hose/dosing pump

11 = Dosing pump of suction hose

25 = Injection valve

12 = Dosing pump

26 = Circulation unit

13 = Touch panel

27 = Mixing pump

14 = Signal column

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ACO Lipufloc dosing station Product description

Design item no. 7980.20.30 26

1

25

2

24

3

23

4

22

5

21

6

20

7

19

8 18

9

17

10

16

11

15

12 13 14

Illustration: 1 = 230-V power socket (rear of the cabinet)

15 = ACO grease separator (optional)

2 = Touch panel

16 = Inlet fittings of grease separator (optional)

3 = Control unit

17 = Connector with mounting

4 = Dosing pump of suction hose

18 = Mixing pump of pressure hose

5 = Level-measuring device for container contents

19 = Empty conduit (on-site)

6 = Cabinet

20 = Connection seal

7 = Transport cart

21 = Suction attachment with foot valve

8 = Diaphragm valve

22 = Container for flocculant

9 = Injection valve

23 = Cover with transparent inlay and tension ring

10 = Cable duct

24 = Cabinet

11 = Circulation unit

25 = Dosing pump

12 = Circulation shaft

26 = Signal column

13 = Float switch 14 = Mixing pump

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ACO Lipufloc dosing station Product description

2.4 Operating principle Model item no. 7980.20.10 and 7980.20.20 in example

Illustration: A dosing pump conveys a small volume of flocculant out of the flocculant container and into the suction pipe of the mixing pump, based on time and volume parameters. The mixing pump extracts treated waste water from the submersible outlet pipe of the grease separator. The treated waste water is thoroughly homogenised together with the small volume of flocculant and is fed back to the grease separator via the connector. To replace the flocculant, simply secure the container to the transport cart and move this unit into the cabinet. The control unit is the central element of the system. All information regarding fill levels and operating statuses can be found here. The touch panel connected to the control unit shows the system configuration and the current operational status. The dosing sequence is programmed at the touch panel subject to the catering establishment. The operational readiness of the system and any faults are also displayed at the signal column. Process technology and the mode of action of the chemical used (flocculant): In the grease separator, the existing stable emulsions are broken up and particulate components are linked together to create large, flaked structures. Depending on their specific density, these flakes move into the grease or sludge collection chamber of the grease separator. The chemical reaction to create bonded structures occurs spontaneously and is not affected by temperature fluctuations or extended operational interruptions. The

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ACO Lipufloc dosing station Product description

running waste water contains noticeably less grease/oil. Empirically, the COD (chemical oxygen demand) parameters are also reduced, as well as the solids concentration. By adding the chemical, a noticeably higher number of substances are removed from the waste water stream overall, which then accumulate in the grease separator. In general, adhering to the standard-based recommendation (see DIN EN 1825-2) for the maximum monthly disposal cycles is not sufficient. Predicting the additional sludge accumulation is very difficult, is only possible with large fluctuation margins and depends very much on the type of operation. Generally, ACO recommends emptying the grease separator at least every three weeks and more often if necessary.

2.5 Control unit 1

2

3

Illustration: 1 = Signal column

3 = Control unit

2 = Touch panel

2.5.1 Signal column ■■

Group alarm; red lamp lights up Causes: ……

Mixing pump excess current

……

Dosing pump excess current

……

Check treatment agent

……

Dose cancelled due to stall, e.g. emptying process of the separator

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ACO Lipufloc dosing station Product description

■■

In operation System is operating without malfunctions; green lamp lights up

2.5.2 Touch panel ATTENTION There are various display options for the touch panel. You can see a selection of these below. Operating personnel must be briefed by ACO Service. Main screen (model item no. 7980.20.10 and 7980.20.20 in example) 1

2

3

OFF ON

4

5

.......... “Scrolling text” ................................. Lipurex -O Fettabscheider Lipurex O grease seperator

Zu To

Ab Off

0%

Circulation Zirkulation Hauptbild

11

Dose settings

10

Dosieranlage ACO Lipufloc ACO Lipufloc dosing

Flockungsmittel Flocculant

Default setting

9

Clear error

8

7

6

Illustration: 1 = "Off" control field 2 = "On" control field

8 = "Clear error" control field

3 = Operation display field

9 = "Default settings" control field

4 = "Malfunctions – scrolling text" display field

10 = "Dose settings" control field

5 = Graphical fill level indicator

11 = "Main screen” control field

6 = Language selection

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7 = Digital fill level indicator

ACO Lipufloc dosing station Product description

Main screen operating elements ■■

Switch on automatic operation Pressing this field switches on automatic operation of the system.

■■

Switch off automatic operation Pressing this field switches off automatic operation of the system.

■■

Clear errors Pressing this field clears all fault messages once the cause has been remedied.

■■

Display or adjust default settings Pressing this field calls up a new screen where the default settings are displayed and can be adjusted.

■■

Display or adjust the dose setting Pressing this field calls up a new screen where the dose setting is displayed and can be adjusted.

■■

Call up main screen Pressing this field calls up the main screen.

■■

ON

OFF

Clear error

Default setting

Dose settings

Main screen

Select German Pressing this field displays the text in German.

■■

Select English Pressing this field displays the text in English.

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ACO Lipufloc dosing station Product description

Main screen display elements ■■

System out of operation If the system is out of operation: the light is off.

■■

System in operation If the system is in operation: Light comes on.

■■

Malfunctions during operation If there is a malfunction, the fault message appears as scrolling text:

■■

……

Mixing pump excess current

……

Dosing pump excess current

……

Check treatment agent

……

Dose cancelled due to stall, e.g. emptying process of the separator

... “Scrolling text” ...

Flocculant fill level The fill level in the container is displayed graphically.

■■

Flocculant fill level The fill level in the container is displayed numerically.

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28 %

ACO Lipufloc dosing station Installation

3 Installation WARNING Risk of electric shock due to improper electric installation ■■

Have work in the interior of the control unit and on the electrical connection carried out by a qualified electrician only.

3.1 Requirements ■■

Frost-free installation room

■■

Flat installation surface with appropriate load bearing capacity

■■

Easily accessible for operation, cleaning and maintenance. At least 600 mm of working space all round

3.2 Installation ATTENTION Installation is carried out by ACO Service. Exception: Installation of the circulation shaft base and the associated add-on system (optional),  Section 3.3 "Services provided by customer"..

3.3 Services provided by customer ■■

To supply energy, a cable (5-core/2.5 mm²) with a 2-m free end must be laid up to the terminal compartment of the control unit.

■■

A cable (dimensions in accordance with local conditions) must be connected to the control unit to forward group alarms to the control centre of the isolated contact,   “Circuit diagram“.

■■

■ATTENTION Install the circulation shaft in accordance with separate instructions,  “Circulation shaft_01702902” instructions.

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ACO Lipufloc dosing station Commissioning

4 Commissioning CAUTION Risk of injury from contact with flocculant ■■

Wear protective equipment,

 Section 1.3 "Personal protective equipment".

■■

Observe safety data sheet,

 Section 2.1 "Scope of delivery".

Risk of infection from contact with waste water ■■

Wear protective equipment,

 Section 1.3 "Personal protective equipment".

The commissioning procedure must be documented, report".

 Appendix 1 "Commissioning

4.1 Default settings on touch panel ATTENTION To ensure that the system functions safely and successfully, the default settings must only be set by ACO Service. The operator must only use the display function of the default settings. 1

System dimensions/rate of mixing pump

NS 2

Select system Fettabscheider Eco-Jet O Zu

Dose

Signal scaling Minimum volume Signal scaling Maximum

Ab

Dosieranlage ACO Lipufloc

... l/h

Flockungsmittel Zirkulation

Fettabscheider Eco-Jet R Zu

... l/h

Ab

Dosieranlage ACO Lipufloc Flockungsmittel Zirkulation

Fettabscheider Lipator Zu

Treatment agent

Empty signal at

2

Ab

Dosieranlage ACO Lipufloc

0 %

Flockungsmittel Zirkulation

Fettabscheider Lipurex O Zu

Ab

Dosieranlage ACO Lipufloc Flockungsmittel Zirkulation

Mixing pump Manual mode

Dosing Manual mode

Fettabscheider Lipurex R Zu

Ab

Dosieranlage ACO Lipufloc Flockungsmittel Zirkulation

Flockungsmittel

3

Main screen

Dose settings

Zirkulation

Default setting

Zu

Ab

Fettabscheider Lipumax

Illustration: 1 = Displays with sample settings 2 = Background image selection fields

22/ 36

3 = Manual control fields

Dosieranlage ACO Lipufloc

ACO Lipufloc dosing station Commissioning

Operating and display elements for default settings ■■

Display settings(examples) Default settings (ACO Service) are displayed.

NS 2

1,2 l/h 0,1 l/h

25

■■

Switch on manual operation of the mixing pump

Mixing pump Manual mode ON

Pressing this field switches on the mixing pump (e.g. service work).

■■

Switch on manual operation of the dosing pump Pressing this field switches on the dosing pump (e.g. service work).

■■

Select background image Pressing a selection field selects a background image for the main screen that matches the grease separator installed (ACO Service).

%

Dosing Manual mode ON

Fettabscheider Eco-Jet O Zu

Ab

Dosieranlage ACO Lipufloc Flockungsmittel Zirkulation

Fettabscheider Eco-Jet R Zu

Ab

Dosieranlage ACO Lipufloc Flockungsmittel Zirkulation

Fettabscheider Lipator Zu

Ab

Dosieranlage ACO Lipufloc Flockungsmittel Zirkulation

Fettabscheider Lipurex O Zu

Ab

Dosieranlage ACO Lipufloc Flockungsmittel Zirkulation

Fettabscheider Lipurex R Zu

Ab

Dosieranlage ACO Lipufloc Flockungsmittel Zirkulation

Flockungsmittel

Zirkulation Zu

Ab

Fettabscheider Lipumax

Dosieranlage ACO Lipufloc

23/ 36

ACO Lipufloc dosing station Commissioning

Dose The following illustration shows the layout of the dose settings screen. The dose is in operation in the time frame shown (with sample values).. ATTENTION To ensure safe and successful operation of the system, the dose settings must only be set by ACO Service. The operator must only use the display function of the dose settings.

Start

End

Dosage

08 : 00

12 : 00

0.40 l/h

16 : 00

22 : 00

0.40 l/h

Main screen

Dose settings

Mo

Tue

Wed Thur

Fr

Sat

Sun

Default setting

Illustration:

4.1.1 Performance monitoring As the operating characteristics of catering facilities can differ greatly, performance monitoring is carried out. For this, sampling/measurements are carried out after a running-in period of around one week with the aid of ACO's own sampling and analysis equipment. The results of the control tests are incorporated directly into the programming of the system. This allows an optimal treatment outcome to be achieved and chemical consumption to be optimised.

4.1.2 Setting automatic operation The results of the control tests are incorporated directly into the programming of the system by ACO Service. This allows an optimal treatment outcome to be achieved and chemical consumption to be optimised.

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ACO Lipufloc dosing station Commissioning

Set the following on the touch panel:: ÎÎ

Press the "ON" control field on the main screen.

ON

Light comes on. System is ready for operation.

To allow for unusual operating conditions such as major events or production expansions, the relevant programmes can be recorded and simply activated by operating personnel

4.2 Day-to-day operation ATTENTION The system may only be used for the purpose for which it is designed,  Section 1.1 "Intended use". Requirements: ■■

In catering establishments, alkaline cleaning agents are preferably to be used as these can reduce the volume of flocculant to be used.

■■

To avoid extended periods of operational interruption caused by a lack of flocculant, ensure you have one container of flocculant in stock. Item no. 0155.01.30; send requests to [email protected]

■■

The flocculant complies with WGK (water hazard class) 1 (= low risk to water) and therefore, for volumes up to 1 m³, there are no requirements regarding the storage facility that go beyond the operational requirements relating to:

■■

……

Fixing and sealing the surface

……

Retention

……

Organisational and technical measures

Regular disposal of the contents of the grease separator: By adding the chemical, a noticeably higher number of substances are removed from the waste water stream overall, which then accumulate in the grease separator. In general, adhering to the standard-based recommendation (see DIN EN 1825-2) for the maximum monthly disposal cycles is not sufficient. Predicting the additional sludge accumulation is very difficult, is only possible with large fluctuation margins and depends very much on the type of operation. Generally, ACO recommends emptying the grease separator at least every three weeks and more often if necessary.

25/ 36

ACO Lipufloc dosing station Commissioning

4.3 Changing the flocculant ATTENTION Automatic operation of the system must be stopped for the duration of the replacement process. To change the container, you must observe the following sequence:

26/ 36

ÎÎ

Unlock the cylinder lock of the lower cabinet door and open the door.

ÎÎ

Loosen the nut of the bulkhead connection on the cover of the container.

ÎÎ

Remove the suction hose.

ÎÎ

Disconnect the plug of the levelmeasuring cable from the male socket of the level-measuring device on the cover.

ÎÎ

Roll the transport cart and the container out of the cabinet.

ACO Lipufloc dosing station Commissioning

ÎÎ

Loosen the safety chain and lift down the empty container from the transport cart.

ÎÎ

Lift the full container that is on hand onto the transport cart – this requires two people – and secure with the safety chain.

ÎÎ

Release the tension ring on the full container and take off the cover.

ÎÎ

Release the tension ring on the empty container and remove the entire cover unit – the cover with transparent inlay and the suction attachment with foot valve and position in or on the full container and re-secure with the tension ring.

ÎÎ

Secure the cover of the replacement container to the empty container with the tension ring.

27/ 36

ACO Lipufloc dosing station Commissioning

ÎÎ

Push the transport cart (3) and the full container (2) into the cabinet (1).

ÎÎ

Insert the plug of the level-measuring cable into the male socket of the levelmeasuring device on the cover.

ÎÎ

Insert the suction hose.

ÎÎ

Tighten the nut for the bulkhead connection.

ÎÎ

Close the door and lock the cylinder lock.

ÎÎ

Ensure that you have a full container of flocculant in stock and dispose of the empty container.

System is ready for operation again.

28/ 36

ACO Lipufloc dosing station Troubleshooting

5 Troubleshooting WARNING Risk of electric shock ■■

Only electricians may work on electrical connections.

■■

Disconnect the control unit from the power supply before commencing troubleshooting.

CAUTION Flooding and risk of infection in the event of improper troubleshooting ■■

Only qualified technicians may work on the system components, 1.2 "Personnel qualification".

Section

■■

Only use original spare parts.

■■

Have ACO Service carry out repairs on the system, Service“.

■■

Avoid contact with waste water and wear protective equipment, 1.3 "Personal protective equipment”.

■■

Avoid contact with flocculant; wear protective equipment,  Section 1.3 "Personal protective equipment” and observe the safety data sheet,  Section 2.1 "Scope of delivery”.

■■

Only work on depressurised connections and cables.

 Page  3 „ACO  Section.

Burns caused by hot surfaces ■■

Allow the motors to cool down.

29/ 36

ACO Lipufloc dosing station Troubleshooting

System malfunctions Malfunction

Cause(s)

Measures

Mixing pump transports nothing or too little

Pressure line or suction pipe blocked

Clean the pressure line or suction pipe

Impeller (pump) blocked

Pump must be serviced (ACO Service)

Worn pump parts

Pump must be repaired (ACO Service)

Mixing pump not running

Defective pump motor

Pump must be replaced (ACO Service)

Pump blocked by foreign body

Pump must be serviced (ACO Service)

Interrupted power supply

Check connections to power supply, reestablish power supply

Automatic mode is switched off

Switch on automatic mode

Pump overload protection has been triggered. Fault cannot be acknowledged

Pump needs to be serviced or repaired (ACO Service)

Mixing pump is leaking

Faulty seal

Seal must be replaced (ACO Service)

Dosing pump delivers nothing or too little

Pressure hose or suction hose blocked

Clean pressure hose or suction hose; replace if necessary

Defective rotor or pressure rollers

Pump must be serviced (ACO Service)

Worn pump parts

Pump must be repaired (ACO Service)

Defective rotor

Pump must be replaced (ACO Service)

Defective rotor or pressure rollers

Pump must be serviced (ACO Service)

Interrupted power supply

Check connections to power supply, reestablish power supply

Automatic mode is switched off

Switch on automatic mode

Pump overload protection has been triggered. Fault cannot be acknowledged

Pump needs to be serviced or repaired (ACO Service)

No connection to power supply

Check connections to power supply, reestablish power supply

Defective control unit

Control unit must be replaced (ACO Service)

No connection to power supply

Check connections to power supply, reestablish power supply

Touch panel faulty

Touch panel must be replaced (ACO Service)

No connection to power supply

Check connections to power supply, reestablish power supply

Defective signal column

Signal column must be replaced (ACO Service)

Dosing pump not running

Control unit not functioning

Touch panel is not functioning

Signal column is not functioning

30/ 36

ACO Lipufloc dosing station Troubleshooting

Fault messages on the touch panel or control unit Display field* Mixing pump excess current

Signal column

Cause(s)

Measures

Maximum current consumption exceeded

Pump must be serviced (ACO Service)

Pump possibly blocked by foreign body

Dosing pump excess current

Pump overload protection has been triggered. Fault cannot be acknowledged

Pump needs to be serviced or repaired (ACO Service)

Maximum current consumption exceeded

Pump must be serviced (ACO Service)

Pump possibly blocked by foreign body

Check treatment agent

Dose cancelled due to stall

Pump overload protection has been triggered. Fault cannot be acknowledged

Pump needs to be serviced or repaired (ACO Service)

Fill level of flocculant container too low

Check the fill level of the flocculant container and top up flocculant if necessary

Level-measuring device faulty

Level-measuring device must be serviced (ACO Service)

Emptying process of the Stop dosing process and grease separator is active; then resume once the fluid level below the strainer disposal process has finished Strainer in the suction pipe of the mixing pump blocked (free-standing installation)

Clean strainer

Mixing pump (submersible pump) blocked or faulty (below ground installation)

Pump must be serviced (ACO Service)

Ball valve closed (freestanding installation)

Check and open ball valve

*On the touch panel and in the display field on the PLC (programmable logic controller, inside the control unit)

31/ 36

ACO Lipufloc dosing station Technical data

6 Technical data

Values

Control unit

Operating voltage:

~ 230 V, 50 Hz

Current consumption:

2A

Degree of protection:

IP 54

Nominal pressure (long-term operation):

3 bar

Max. delivery performance:

2 l/h

Power consumption P1:

20 W

Max. delivery performance:

300 l/min

Max. delivery head:

10 m

Power consumption P1:

350 W

Degree of protection:

IP 55

Max. delivery performance:

162 l/min

Max. delivery head:

6m

Power consumption P1:

360 W

Degree of protection:

IP 68

Weight/item no.:

Approx. 315 kg/7980.20.10

Weight/item no.:

Approx. 315 kg/7980.20.20

Weight/item no.:

Approx. 370 kg/7980.20.30

System

Mixing pump (submersible pump)

Mixing pump (centrifugal pump)

Specifications

Dosing pump

System

820

650

Dimensional drawings

Ø500

Illustration: container

32/ 36

500 x 300

Illustration: circulation unit/freestanding installation

ACO Lipufloc dosing station Technical data

ca. 1070 ca. 1300

50

R 1"

Ø110 (DN 100) Ø160 (DN 150) Ø210 (DN 200) 200

Illustration: circulation unit/below ground installation

657 680

770

930

Ø160

460

1890

Illustration: connector/freestanding installation

Ø480

1.450

753

Illustration: Cabinet

Illustration: circulation shaft base (construction phase I)

Circuit diagram The complete circuit diagram is provided with the control unit; copies can be requested from ACO Service if lost,  Section Introduction "Service".

33/ 36

AWRG-Anlage Appendix 1: Commissioning report

Appendix 1: Commissioning report Commissioning and briefing by ACO Service in the presence of the person responsible for acceptance as well as the system operator. Date of commissioning: Date of handover: System

Serial no.

Year of construction

Product

Item no.

Model

ACO Lipufloc

7980.20.10

For ACO NS 4-25 grease separators with control unit (OA, OSE, OAE, RA, RSE, RAE); free-standing installation

ACO Lipufloc

7980.20.20

ACO NS 4-25 grease separators without control unit (O, OD, OS, R, RD, RS); Free-standing installation

ACO Lipufloc

7980.20.30

ACO grease separators; below ground installation

Location Building/room: Use:

Commercial usage

Street: Town/city: Responsible persons ACO Service Name:

ACO Service

Telephone no.:

03 69 65 / 81 9 -4 44

Fax no.:

03 69 65 / 81 9 -3 67

Email:

[email protected] ACO Service

Address:

Im Gewerbepark 11c 36457 Stadtlengsfeld, Germany

34/ 36

Party responsible for acceptance

System operator

AWRG-Anlage Appendix 1: Commissioning report

Check list for commissioning (by ACO Service) Inspections

OK

NOK

Yes

No

Control unit protected by fuses in accordance with IEC regulations or national and local directives Operating voltage and frequency Motor protection switch: Check by briefly unscrewing individual fuses (two-phase operation) Function test of mixing pump Function test of dosing pump Function test of suction attachment with foot valve Function test of level-measuring device Function test or setting of diaphragm valve Function test of float switch (version: below ground installation) Settings in the menu of the control unit Tightness: system, fittings, cables and connections Fault message equipment: fault messages on touch panel, in display field (PLC) and on signal column Remote signal equipment (optional)

Briefing (by ACO Service) Briefing

Remarks

Briefing:

Functions, control, operating information, troubleshooting, maintenance requirements

Handover::

Operating instructions

Remarks:

Signature (ACO Service): Signature (party responsible for acceptance): :

35/ 36

ACO Building Drainage

ACO Passavant GmbH Im Gewerbepark 11c D 36457 Stadtlengsfeld Tel.: + 49 36965 819-0 Fax: + 49 36965 819-361 www.aco-haustechnik.de

ACO. The future of drainage.

ACO Building Drainage Instructions for use

Issued: 2015–06–01

Circulation shaft For installation in the ground; with integrated sampling pot for the later replacement and incorporation of the ACO Lipufloc circulation unit

For safe and proper use, please read the instructions for use and other literature supplied with the product carefully, provide end users with them and keep them safe throughout the service life of the product.

0170.29.02_V1.1_EN

Translation of the original instructions for use

Circulation shaft I ntroduction

Introduction ACO Passavant GmbH (hereafter referred to as „ACO“) would like to thank you for the confidence you have placed in us. You have purchased a circulation shaft, which is a stateof-the-art piece of equipment that was tested prior to delivery as part of our quality control process to ensure it is in proper condition. Illustrations in these instructions for use are provided for basic understanding and may differ from your version of the product and the respective installation situation.

Service Please feel free to contact ACO Service if you require further information. ACO Service Im Gewerbepark 11c

Tel.: + 49 (0) 3 69 65 / 81 9 -4 44 Fax: + 49 (0) 3 69 65 / 81 9 -3 67

36457 Stadtlengsfeld, Germany

[email protected]

Warranty For information on warranties, see „General Terms and Conditions“,  http://www.aco-haustechnik.de/agb

Use of symbols Symbols are used to draw your attention to particular information in these operating instructions as follows: Tips and additional information to make your work easier ■■

Bullet point

ÎÎ

Steps to be carried out in the specified order References to further information in these operating instructions and in other documents Warnings

2/ 20

Circulation shaft Contents

Contents 1

For your safety......................................................................................... 4 1.1 Intended use.............................................................................................. 4 1.2 Personnel qualification................................................................................ 4 1.3 Personal protective equipment..................................................................... 5 1.4 Transport and storage................................................................................ 5 1.4.1 Transport........................................................................................ 5 1.4.2 Storage.......................................................................................... 6 1.5 Disposal.................................................................................................... 6

2

Product description................................................................................. 7 2.1 Product features......................................................................................... 7 2.2 Components.............................................................................................. 7 2.3 Suggested installation................................................................................. 8

3

Technical data......................................................................................... 9 3.1 Circulation shaft......................................................................................... 9 3.2 Accessories (optional)............................................................................... 10

4 Installation.............................................................................................11 4.1 Conditions............................................................................................... 11 4.2 Preparatory work...................................................................................... 12 4.3 Installation work....................................................................................... 12 4.3.1 Excavating the pit.......................................................................... 12 4.3.2 Inserting the container.................................................................... 13 4.3.3 Connecting the inlet line and drain line.............................................. 13 4.3.4 Connecting the connecting line........................................................ 14 4.3.5 Installing add-on systems in load class A15 or B125.......................... 14 4.3.6 Filling the pit.................................................................................. 17 4.3.7 Add-on system in load class D400................................................... 17

3/ 20

Circulation shaft For your safety

1 For your safety Read the safety instructions before installing or using the circulation shaft in order to prevent injuries and damage to property.

1.1 Intended use Intended use The circulation shaft is to be installed in the ground downstream of a grease separator. It features an integrated sampling pot. If the grease separator system is equipped or retrofitted with an ACO Lipufloc dosing station, the sampling pot is replaced with a circulation unit. No other possible uses or applications, nor modifications, are permitted. Non-approved parts Installing non-approved parts compromises safety and voids any warranty provided by ACO. Only use original parts from ACO or ACO-approved spare parts when replacing components.

1.2 Personnel qualification Operations

Person

Knowledge

Transport, storage

Dispatchers, stockists

Proof of load safety training, safe handling of lifting and sling equipment Pit excavation and filling

Underground installation, disassembly

Qualified technicians

Safe handling of machinery Safe handling of tools Installing and connecting pipelines and connectors

Disposal

4/ 20

Qualified technicians

Correct, environmentally compatible disposal of materials and substances, knowledge regarding recycling

Circulation shaft For your safety

1.3 Personal protective equipment Personnel must be provided with personal protective equipment and its use checked by supervisors. Mandatory sign Explanation Safety shoes offer good non-slip protection, especially in wet conditions, as well as high puncture resistance (e.g. in the case of nails) and protect feet from falling objects (e.g. during transportation and installation) Safety helmets protect you from head injuries e.g. from falling objects or blows

Protective gloves protect hands from minor cuts and bruises.

1.4 Transport and storage The circulation shaft is supplied attached to a pallet (Euro pallet) and foil-wrapped for protection against moisture and dirt.

1.4.1 Transport ATTENTION During transportation: ■■

Never drive a forklift or lifting truck directly under the circulation shaft.

■■

If possible, transport the circulation shaft on a Euro pallet.

■■

If possible, do not remove the packaging and transport safety devices until the system has reached the installation location.

■■

Check the load bearing capacity of the lifting gear: It must be at least equivalent to the indicated weight plus safety margin.

■■

During transport by two people, the surrounding ring is to be used as the contact surface on the circulation shaft or attachment piece (accessory) and the upper end collar can be used for additional support.

5/ 20

Circulation shaft For your safety

■■

When transporting the circulation shaft and the shaft parts (accessories) with a crane or crane hook: ……

Fasten the belts to the pallet or to system components that can bear the load.

……

Never stand under a suspended load.

……

Make sure that no other people can access any part of the danger area.

……

Avoid swinging movements during transportation.

……

The connecting points on the circulation shaft are designed for the circulation shaft load. Use 2nd suspension gear, min. 5 m long with shackle NG 5 according to DIN 82101.

……

For the load distribution plate (accessory), use 3rd suspension gear, min. 2–3 m long with shackle NG 1 according to DIN 82101.

……

For the adapter plate and cover (accessories), use a shaft ring suspension gear with clips.

1.4.2 Storage ATTENTION Incorrect storage can cause damage to the circulation shaft. The following steps must be taken: ■■

Store and cover the circulation shaft in an enclosed, dry, dust-free and frost-free room.

■■

Avoid temperatures outside the range of 0°C to +60°C.

1.5 Disposal Before disposing of the circulation shaft, completely drain and clean it. Incorrect disposal constitutes an environmental hazard. Comply with regional disposal regulations.

6/ 20

■■

Separate components by materials

■■

Recycle components

Circulation shaft Product description

2 Product description 2.1 Product features ■■

Material: polyethylene LLP-HD

■■

Integrated sampling pot with 160-mm gradient

■■

Connections:

■■

……

DN 150 inlet

……

DN 150 outlet

……

Gradient between inlet and outlet: 160 mm

……

DN 100 connection sockets

Add-on systems (optional): ……

Load class A15: foot-traffic version – ideal for courtyards and green areas

……

Load class B125: car-traffic version – perfect for driveways and parking areas

……

Load class D400: HGV-traffic version – the safe solution for heavy goods vehicles and storage areas as well as the hard shoulders of roads

2.2 Components 1

2

3

4

5

6

7

8

Illustration: 1 = DN 150 Inlet

5 = DN 150 outlet

2 = Sampling pot

6 = DN 100 connection socket (closed)

3 = Container

7 = DN 100 connection socket/standard (closed)

4 = Connecting pipe

8 = DN 100 connection socket (closed)

7/ 20

Circulation shaft Product description

2.3 Suggested installation 1

2

3

4

5

8 7

6

Illustration: 1 = ACO Lipufloc dosing station 2 = High-pressure pump (high-pressure internal cleaning of grease separator 3 = Filling device (grease separator) 4 = Grease separator 5 = Circulation shaft with sampling pot (construction phase 1)

8/ 20

6 = Circulation shaft with submersible pump (construction phase 2) 7 = Connecting line (empty conduit) to grease separator 8 = Connecting line (empty conduit) to circulation shaft

20°

130

125

20°

Ø800

20° Ø600

20° 20° 20° Ø600

Ø800

Ø800 125

Ø600

20°

Ø600

20° 950 - 2.070

130

125 (B125) 80 (A15) 130 125 (B125) 80 (A15)

Ø480

700 bzw. 1.690

700 bzw. 1.690

20°

130

125

Ø480 38°

130

1.450 Ø600

1.600

770

930

160

Ø160

970 - 2.070 (B125) 805 - 2.070 (A15)

125 (B125) 80 (A15) 130 125 (B125) 80 (A15)

Ø600

770 970 - 2.070 (B125) 805 - 2.070 (A15) 970 - 2.070 (B125) 805 - 2.070 (A15)

130

160 Ø600

950 - 2.070

770

160

Ø160

930

3.1 Circulation shaft

1.600

20° 38° 125 (B125) 80 (A15)

38°

130

930

695 (B125) 650 (A15) 695 (B125) 430 650 (A15) Ø160 430

130

430

695 (B125) 650 (A15)

3 Technical data

950 - 2.070

700 bzw. 1.690

125 (B125) 80 (A15)

Ø480

1.600

Ø480

970 - 2.070 (B125) 805 - 2.070 (A15)

130

Ø600

950 - 2.070

770

160

125 (B125) 80 (A15)

Circulation shaft Technical data

Ø600

1.450

Illustration: Class A15 and B125, installation depth Tmin 1.450

Illustration: Class D400

1.450

Illustration: Class A15 and B125, installation depth >Tmin bis Tmax

Ø600

9/ 20

Circulation shaft Technical data

Specifications

Values

Inlet/external diameter

DN 150/160mm

Outlet/external diameter

DN 150/160mm

Connection for empty conduit/external diameter

DN 100/110 mm

Empty weight:

75 kg

Dimensions:

1,450 x 1,350 x 1,400 mm (approx. L x B x H)

3.2 Accessories (optional) Unit

Individual parts ■■ ■■

Add-on system, class A 15 (load 1.5 t)

■■

■■ ■■ ■■

Add-on system, class B 125 (load 12.5 t)

■■

■■

■■ ■■ ■■

Add-on system, class D 400 (load 40 t)

■■

■■

■■

10/ 20

Manhole cover, class A15 Attachment piece, 750 mm high (optional) Attachment piece, 1740 mm high (optional) Operating key Manhole cover, class B125 Adapter plate Attachment piece, 750 mm high (optional) Attachment piece, 1740 mm high (optional) Operating key Manhole cover, class D400 Adapter plate Load distribution plate, 200 mm high and Ø1,550 mm (optional) Attachment piece, 1,600 mm high Operating key

Illustration

Circulation shaft Installation

4 Installation ATTENTION Ensure personnel have the necessary qualifications, “Personnel qualification“.

 Section 1.2

4.1 Conditions Installation depth ATTENTION The circulation shaft must not be installed deeper than 3.00 m into the ground. Installation in the event of ground water ■■

■■

Load class A15 and B125: ……

Buoyancy-proof at ground water levels of up to 0.5 m below the site surface

……

In-situ concrete casing is required for higher levels of ground water: Concrete ring >Ø1,600 x 150 mm positioned over container rib

Load class D: ……

Buoyancy-proof at ground water levels up to the site surface without additional measures

Pit ■■

Excavation must be performed according to DIN 18300 and embankment/working room/shoring must be performed according to DIN 4124

■■

In cohesionless soil and soft, cohesive soil, the pit embankment inclination must be ≤ 45° and less than 60° in firm or semi-solid cohesive soils.

■■

Steeper embankments must be expertly and appropriately secured with shoring and other methods.

■■

Foundations must be laid on cohesionless soil (group G1 according to ATV-DVWK-A127 or soil groups GW, GE, GI, SW, SI or SE according to DIN 18196).

■■

Without traffic load, a well-compacted, cohesionless soil (e.g. gravel sand 0–32) is sufficient.

■■

The underfilling must be at least 30 cm thick and compacted to a Proctor density of Dpr ≥ 97%.

■■

An evenly level contact area must be permanently ensured for the container base.

11/ 20

Circulation shaft Installation

4.2 Preparatory work The container has four DN 100 connection sockets,  Section 2.2 “Components“ and  Section 3.1 “Circulation shaft” for the connection of the connecting line (empty conduit) of the container to the installation location of the ACO Lipufloc dosing station. A DN 100 socket seal is supplied loose. ÎÎ

Choose a connection socket (recommendation X).

ÎÎ

Drill out the closed socket base using a keyhole saw (max. Ø100 mm).

ÎÎ

Lubricate the socket and socket seal with acid-free grease.

ÎÎ

Insert the socket seal into the socket.

X

4.3 Installation work 4.3.1 Excavating the pit Requirements:

12/ 20

■■

The pit should be approx. Ø3,000 mm.

■■

The circulation shaft is to be positioned downstream of the grease separator.

ÎÎ

Excavate and secure the pit.

ÎÎ

Create the underfilling.

Circulation shaft Installation

4.3.2 Inserting the container ÎÎ

Insert the container and horizontally align.

4.3.3 Connecting the inlet line and drain line ATTENTION Before the inlet line and drain line are connected, the pit must be filled up to the connection height of the inlet line and drain line,  Section 4.3.6 “Filling the pit“. Requirements: ■■

To avoid blockages, do not constrict the connecting lines.

■■

Connecting lines must be laid at a gradient of at least 2% (1:50) in the direction of flow.

ÎÎ

Connect DN 150 waste water inlet line (drain line of grease separator) to connection port (e.g. pipe connector, push-on socket).

ÎÎ

Connect DN 150 waste water drain line to connection port (e.g. pipe connector, socket tube).

13/ 20

Circulation shaft Installation

4.3.4 Connecting the connecting line ATTENTION Before the inlet line and drain line are connected, the pit must be filled up to the connection height of the inlet line and drain line,  Section 4.3.6 “Filling the pit“. Requirements: ■■

The connecting line (empty conduit) must be laid from the installation location of the ACO Lipufloc dosing station up to the circulation shaft (container) at a gradient of at least 2% (1:50).

■■

Do not use pipe bends greater than 30°.

■■

High-quality taut wire (for one hose and two connecting cables) must be inserted directly into the empty conduit.

ÎÎ

Connect the DN 100 connecting line to the connection socket (lubricate spigot and socket seal with acid-free grease and insert pipe).

4.3.5 Installing add-on systems in load class A15 or B125 Cutting to length and installing the attachment piece

H1 = 30 (A15) 210 (B125)

1 2

X

3

H

40

4 5

115

6

Illustration: 1 = Manhole cover, A15 or B125

4 = Interstices

2 = Adapter plate (only for B125)

5 = Retaining ring: Ø810 mm and 30 mm thick

3 = Attachment piece: 750 mm (25 kg) or 1,740 mm 6 = Sealing ring: Ø780 mm and 20 mm (50 kg) high

14/ 20

Circulation shaft

ÎÎ

Determine dimension X (top edge of container to top edge of site).

ÎÎ

Apply dimension H (X - H1 + 115 mm) to the attachment piece supplied and separate at the next interstice.

ÎÎ

Fit the retaining ring in the second groove.

ÎÎ

Fit the sealing ring in the first groove.

ÎÎ

Lubricate the sealing ring and the surface of the „container collar“ with acid-free grease.

ÎÎ

Insert the attachment piece into the container and horizontally align.

H

Installation

15/ 20

Circulation shaft Installation

Installing the manhole cover 1 2 3 4

Illustration: 1 = Manhole cover A15 (145 kg) or B125 (110 kg)

3 = Flat seal

2 = Adapter plate (170 kg, only for B125)

4 = Container or more specifically the attachment piece

ATTENTION ■■

Before installation, all contact surfaces must be cleaned.

■■

Before the manhole cover is installed, the pit must be filled up to the connection height of the manhole cover,  Section 4.3.6 “Filling the pit“.

A15: ÎÎ

Place the flat seal on the surface.

ÎÎ

Insert the manhole cover into the „holder“.

B125: Commercially available supporting rings can be installed between the manhole cover and the adapter plate for the purposes of alignment with the top edge of the site.

16/ 20

ÎÎ

Place the flat seal on the surface.

ÎÎ

Insert the adapter plate into the „holder“.

ÎÎ

Apply mortar bed (  “information provided by mortar supplier”) to the surface of the mortise.

ÎÎ

Insert the manhole cover into the mortise of the adapter plate and align.

Circulation shaft Installation

4.3.6 Filling the pit Requirements: ■■

The building materials used and the installation process must not result in any damaging distortions, damage or inappropriate loading conditions for the container or attachment piece.

■■

The circulation shaft must be embedded all the way round (≥ 0.50 m) with a sand and gravel mix with a low fine-grain content or a sand and broken stone mix of the soil group GW or GI according to DIN 18196.

■■

The layered filling (≤ 30 cm high) must be compacted with a light-weight compactor to a Proctor density of Dpr ≥ 97%.

■■

The frame of the manhole cover must not be higher than the covering; rather, the covering should be somewhat higher and raised at the edge of the frame.

■■

When applying the last covering (e.g. asphalt surface), the manhole cover must not be moved any more.

■■

The add-on system must not be loaded until the pit is completely full and the materials used for filling have set sufficiently.

ÎÎ

Fill the pit.

4.3.7 Add-on system in load class D400 Cutting to length and installing the attachment piece

340

260

1 2

8 X

4 H

40

7

3

5 115

6

Illustration: 1 = Manhole cover D400

5 = Retaining ring: Ø810 mm and 30 mm thick

2 = Adapter plate

6 = Sealing ring: Ø780 mm and 20 mm

3 = Load distribution plate: Ø1550 x 200 mm high (700 kg)

8 = Sealing ring: Ø780 mm and 20 mm

7 = Attachment piece: 1600 mm high (50 kg)

4 = Interstices

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Circulation shaft Installation

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Determine dimension X (top edge of container to top edge of site).

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Apply dimension H (X - 340 + 115 mm) to the attachment piece supplied and separate at the next interstice

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Fit the retaining ring in the second groove.

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Fit the sealing ring in the first groove.

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Lubricate the sealing ring and the surface of the „container collar“ with acid-free grease.

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Insert the attachment piece into the container and horizontally align.

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Fit the sealing ring over the spigot.

H

ATTENTION Before the load distribution plate is installed, the pit must be filled up to the connection height of the load distribution plate,  Section 4.3.6 “Filling the pit“.

Circulation shaft Installation

Guide the load distribution plate over the spigot and fix so that the height difference between the top edge of the load distribution plate and street level is 260 mm.

260

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Installing the manhole cover 1 2 3

Illustration: 1 = Manhole cover D400 (110 kg)

3 = Load distribution plate

2 = Adapter plate (170 kg)

ATTENTION ■■

Before installation, all contact surfaces must be cleaned.

■■

Before the manhole cover is installed, the pit must be filled up to the connection height of the manhole cover,  Section 4.3.6 “Filling the pit“. Commercially available supporting rings can be installed between the manhole cover and the adapter plate for the purposes of alignment with the top edge of the site.

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Apply mortar bed (  “information provided by mortar supplier“) to the surface of the mortise of the load distribution plate.

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Insert the adapter plate into the „holder“.

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Apply mortar bed (  “information provided by mortar supplier“) to the surface of the mortise of the adapter plate.

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Insert the manhole cover into the mortise of the adapter plate and align.

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ACO Building Drainage

ACO Passavant GmbH Im Gewerbepark 11c D 36457 Stadtlengsfeld Tel.: + 49 36965 819-0 Fax: + 49 36965 819-361 www.aco-haustechnik.de

ACO. The future of drainage.